Process for treating wood and products

ABSTRACT

Wood cellulose is treated with a reactive silicate. The reaction is done to cellulose within the wood and may be catalyzed with acid or base catalysts or a carbon silicon halogen combination which produces in situ acid catalysts or a different combination to produce an in situ base catalyst which replaces some of the molecules or atoms within the cellulose structure with silicon, boron or other hydrophobic or anti-degrading agents. Preferably an organic solvent, such as alcohol is used to accelerate the reaction with the water in the wood. Here, the hydroxyl (OH) group on some or all of the cellulose molecules is partially replaced with silicon or an alternative atom or molecule to changes the character of the wood. The process may be modified to insert a preliminary step of adding a reactive agent to be locked into the wood. Manufacturing techniques to enhance the process using ultrasound or other wave generating techniques are also taught.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent is a continuation in part of Utility patent application Ser.No. 09/885,642 filed Jun. 20, 2001, which is the non-provisionalapplication of Provisional Patent Application 60/213,198 filed Jun. 21,2000. It is also a CIP of Utility patent application Ser. No. 09/788,165filed Feb. 15, 2001.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the treatment of wood. The inventionrelates to the treatment of wood in such a way that the chemicalstructure of all or part of the cellulose is altered to preserve thewood.

2. Description of Related Art

Past wood treatments consist of various chemical and dry kiln loadingand unloading techniques for wood. The cellulose of the wood is areactant of the present invention.

Scientists and researches have been seeking an effective silicon basedwood treatment for decades. Studies have suggested that silicon iseffective in the treatment of wood. Difficulties have arisen, however,in how to effectively transport the silicon into the wood and keep itthere.

Wax resins have also been attempted with unsatisfactory results. Boroncompounds may function as insect repellents and may be used in thetreatment of wood products. The biggest drawback of the use of boron inthe treatment of wood is that it leeches out of the wood too quickly.This leeching has the detrimental effect of leaving the treated wood ina poorly protected state after a relatively short period of time.

Current wood treating techniques require that the wood be dried prior tothe treatment process. If the wood is naturally “wet” (or green) thecarrier is less efficiently absorbed and cannot effectively distributethe treatment chemical. Wood may also be wet from external sources suchas storage, transport, cleaning, weather, etc., and require drying.

Such drying may be accomplished in a variety of ways and at significantexpense. Larger wood pieces (i.e. railroad ties, utility poles, timbers,etc.) are typically “air dried”. This process requires that the wood bestored in vast lots where it will naturally dry due to exposure to thesun and air. In addition to the costly management, there is the cost ofinventory. Most wood that is air dried is required to sit idle on a lotfor 6-12 months. The financial burden of having to carry these enormousinventories of dormant wood has been estimated at nearly $100 millionannually for the railroad industry alone.

Another common drying technique is kiln drying. This is a significantlyfaster process than air drying, but the expense involved in theconstruction of the drying buildings and the energy utilized to forcethe wood to dry is significant. Cut timber needs to be kiln or air driedto a level of approximately 14-20% moisture level prior to treatmentwith existing technologies. This process is costly in terms of time (airdrying) or money (kiln drying) and adds a significant cost to theoverall treated product. The drying process is necessary to supporttransport of the carry of the chemicals and provide open volume toaccept the treatment solution. A “green” piece of wood will not allow aprior art treatment carrier to enter to an acceptable level.

The treatment methods most commonly used today utilize oil (in the caseof creosote) or water (in the case of Chromated Copper Arsenate (CCA))as the carrier to deliver chemical into the vessels and voids of thewood. These carriers are used with force to place chemicals inside ofthe wood to treat the wood. There is little or no chemical interactionor reaction with the cellulose of the wood itself. Several factorsaffect the levels of benefit to the treated wood using current methodsincluding:

-   -   The concentration of the chemical in the carrier;    -   The pressure exerted on the treatment solution to “force” it        into the wood; and    -   The amount of time the wood remains under pressure during the        treating process.

These variables can be adjusted to produce different “grades” of treatedwood for different end products. For example, a piece of dimensionallumber will not normally be as thoroughly treated as a railroad crosstie which will be in direct contact with the ground, or common outdoordecking. Typically, the higher the concentration of chemical to itscarrier and the longer the treating time the higher the overall cost oftreatment.

Water and oil carriers are poor carriers. While they carry the chemicalinto the wood they also have detrimental effects and reduce the qualityof such treatments. A standard cubic foot of untreated wood will absorbas much as 3.5 gallons of water or oil during a normal treatmentprocess. The carrier water or oil remain in the wood adding weightwithout providing additional treating value. Over time or under changedconditions from those during treating, such carrier may escape the woodand degrade treatment quality. Further, the effect of such carrierscontained in the wood over time on the desired treatment or quality ofthe treated may be varying.

U.S. Pat. No. 5,652,026 to Saka discloses a water based treatment basedon the creation of oligomers outside of the wood.

Polish Patent 148704 to Maciejewski teaches the use of a mixture ofmethylsiloxane, phenylsiloxane and vinyltrichlorosilane in toluene withsubsequent curing to make a coating on metal, concrete or wood. Themechanism of this coating involves co-polymerization of the vinylsilanewith the siloxanes on curing on the surface of the metal, concrete orwood. The reagent does not react with the metal, concrete or wood butforms a coating on the surface only.

A paper by Stabnikose titled “New Methods of Wood Preservation”discloses the use of organic solvents which are non-hydrophillic and donot allow adequate penetration and retention of silicates in the wood.

Non-hydrophilic organic solvents, such as gasoline and benzene do notmix with water [being highly hydrophobic] and therefore a 5-10% solutionin benzene would not penetrate the interior of wet wood. There would beconsiderable evolution of hydrogen chloride gas that is injurious toworkers, environment and damages wood with the benzene.

Nasheri, U.S. Pat. No. 5,871,817 is correct in teaching that boron isintroduced into wood, but not bonded in the prior art. It is indicativeof the failure of prior art to use boron with bonding reagents. Nasheriis also relevant in that it shows a method in the prior art ofintroducing additives in the wood. If this type of invention ispracticed in advance of the process taught in this application, theboron may be trapped in the wood improving the longevity of the woodproduct once it is exposed to environmental pressures.

Historically certain treatments have been taught in the treatment ofcellulose but only after it is extracted from raw wood and the presentinvention seeks to improve on that by describing a method and a specificproduct which can be utilized and created in order to change thestructure in native wood, chip wood derivatives, a living tree, intimber, poles or wood composites.

BRIEF SUMMARY OF THE INVENTION

Applicants have invented a solution for use in treating wood and woodproducts. The solution is comprised of reactants which chemically reactwith wood and its constituents. When the solution comes in contact withwood, a reaction occurs between the reactive components of the solutionand the wood cellulose resulting in a reaction product improving thewood's strength and durability while simultaneously rendering the woodresistant to water, fire, rot, fungus, insects and many otherenvironmental factors.

Prior to Applicants' invention, there has been no way to satisfactorilyhave the chemicals remain in the wood for extended periods of time. WithApplicant's invention, the desired chemicals are absorbed into andbecome part of the wood. Chemical equivalents may also be used.

The carrier for Applicant's invention works with the molecules of thewood. Applicant's invention is drawn into the wood along concentrationgradients and by other physical processes which result from the reactionof reactants with the molecules of the wood. The reactive chemical ofApplicant's invention reacts with the molecules of the wood and maydisplace the water and other liquids inside the wood. Thus, through thechemical's molecular reaction, of a tough, highly resistant polymerproduct (referred to as a matrix or shield) results. Because the wooddraws Applicant's invention into the wood, there is no need to usehigh-pressure to treat the wood. This is a drastic departure from thecentury old process of utilizing high pressure to force various chemicaland treating compounds into the wood.

Because Applicant's invention is drawn into the wood, it may be employedon a “green” piece of wood. Applicant's invention, in a departure fromearlier technology, is effective on wood and wood products that are notdried or bone dry. The presence of moisture in the wood, or wetness inthe wood, provides beneficial effects in the utilization of thisinvention. The chemical reaction of Applicant's invention is acceleratedby the reaction or mixture with the water and other natural liquidsinside a piece of wood. The Applicant's invention is drawn into wetwood, participates in reaction and may expulse the excess water andother liquids originally contained within the wood. It can act as acombination treatment and water displacing (i.e. drying by water volumereplacement) process in one step. Applicant's invention can beconsidered for demonstrative purposes as displacing some of the volumeof the liquids present in the wood or wood product and replacing thatdisplaces volume with its own. Applicant's invention may drive outfluids of the wood to allow for its own impregnation into the wood andreaction with the wood and wood constituents. If so, the waters may beremoved from the solvents as an additional step in order to preventthese from slowing or stopping the reaction.

The applicant's invention is a heat generating, exothermic reactiondriven to completion by the products used and the method in which theyare introduced into the wood from the hydrophillic organic solvent intothe moisture of the wood.

Upon treatment with Applicant's invention, water and other liquids areless able to enter the wood. With the molecular change in the wood'snatural liquids and the creation of a protective polymer which may beproduced throughout the woods thickness, the wood is naturally andpermanently, protected from water; rot; insects; decay, etc.

Tests show that wood treated with Applicant's invention in its preferredembodiment is:

-   -   Waterproof,    -   Decay resistant,    -   Insect resistant, and    -   Stronger than before treatment.

Applicant's invention has been able to incorporate all of the benefitsattributed to both silicon and boron, individually or in combination,and lock those benefits within the wood. By using the natural liquids ofthe wood to “pull” or enable transport of the chemical into the woodwhile allowing the simultaneous reaction of Applicant's reactants withthe wood cellulose, Applicant's invention displaces these liquids withthe molecules of boron and silicon and creates a polymer “shield” basedon the matrix defined by the cellulose polymers to encapsulate or affixa bond to the solids thereby providing protection to the wood.

The result is a wood product that is nearly “petrified” and thatstrongly resists water, rot, insects and other ailments common to wood.Water “beads” on top of wood treated with Applicant's invention.

This same treatment disclosed in the preferred embodiment works onaftermarket wood products such as paper products, wood composites, andother cellulose paper products.

Current treatment processes require an additional chemical and treatmentprocess to provide a minimal level of fire retardant. Applicant'sinvention can be enhanced to impart fire retardency. This enhancementdoes not require any additional conventional equipment and can becompleted as part of the application of inventive process by adding fireretardant chemicals as part of the reactants or by adding fire retardantchemicals before the other reactants are added.

Existing treatment processes require that different wood products betreated at different levels depending on the specifications of the enduse of the wood product. These different levels are primarily measuredin pounds of solid chemicals per cubic foot of wood. In this manner awood product used above ground, will in past art, have less chemical viathe treatment process than one intended as a permanent wood foundation.

Products produced with Applicant's invention may provide environmentalhealth and safety benefits. On the environmental front, many within theindustry recognize an obligation to protect the environment.

Wood treated with Creosote must be handled very carefully because oftoxicity. Railroad workers, utility pole workers and others who handlecreosote treated wood register complaints of swelling hands, sores andblisters from contact. Applicant's invention treated wood is safe andcan be handled without gloves or other protective equipment after it hasbeen treated.

Though claimed to be environmentally clean, wood treated with Creosoteor CCA must be disposed of according to very specific guidelines so asnot to harm the environment. There are no such regulations expected forApplicant's invention.

Applicant's invention allows wood to be treated without altering theshape of the wood or causing swelling. The chemical can also be used asan after-market treatment product. The after-market product will beslightly different than the commercial product, typically in its levelof strength. This is important since many existing structures and woodproducts can receive the benefits of Applicant's invention. Anticipatedafter-market examples include treating wood frame houses to controltermite and/other bug infestation; treatment of previously installedrailroad ties; utility poles; decking, etc. such that they receive thebenefits of Applicant's invention.

There is a strong market need for Applicant's invention. The woodindustry produces approximately 90 billion board feet that currently isnot treated or is treated in an ineffective manner. The benefits of woodas a material are recognized and the need for better, and more efficientwood keeps growing. Wood used in specific market segments such as theconstruction of mobile homes, wood decking in tractor trailers, and allwood or wood products allowing the Applicant's invention reaction willbenefit significantly from a wood treatment that would render the woodwaterproof; fire retardant; insect and decay resistant.

The inability of the treating industry to penetrate more than 10% (+/−)of the wood industry due to the severe limitations of the currenttreating processes has created a desire to discover new methods oftreating that will provide the benefits required by the industry.

Another use for Applicant's invention is in the manufactured woodsegment of the market. Manufactured wood is comprised primarily ofOriented Strand Board (OSB) and Particle board. There are twosignificant drawbacks to manufactured wood, however. First is its levelof fire retardant. While acceptable for many uses it does not have ahigh enough fire retardant level to be used in as many places as themarket requires. Second is its negative characteristic of swelling whenit comes in contact with water.

Using Applicant's invention as a treatment for manufactured woodproducts or for the raw material used in manufactured wood would solvethese in some applications.

Applicant's invention reacts with the natural components of wood. Theend result is a piece of wood that has superior resistance to water,fire, rot, insects, etc.

Current treatment processes use oil, water or other carriers totransport treating chemical into the wood. A significant portion ofthese carriers remain in the wood often causing swelling and/or warpingof the wood. Applicant's invention causes no such alterations.

Unlike current treatment processes, wood treated with Applicant'sinvention does not gain significant weight. This is due to its uniquenature of using the liquids within the wood as the agent to react andcarry the chemical into the wood. Current treatments use oil, water orother carriers to transport chemicals into the wood. These carriersthemselves remain in the wood adding as much as 25 pounds to every cubicfoot of treated wood. Wood treated with Applicant's invention has asmall or even weight gain based on a theorized replacement of certainliquids in the wood and the lack of heavy molecular additives in manyembodiments. Equally important, the reactants are drawn out of thesolvents so that no liquid solvent is added to the wood.

Whether treated after the manufacturing process or by treating the woodcomponents prior to manufacture, Applicant's invention is an excellenttreatment for manufactured wood products.

Applicant's invention reacts with aqueous liquids in wood and itsconstituents. The chemical reaction may also produce a discharge, suchas HCl which can act as a catalyst for the propogation with non-halogenreagents. One step in the process may include the neutralization ofgenerated by-products. Smaller amounts of acid may be used as catalystsfor non-acid generating chemicals in the embodiments.

Because wood treated with Applicant's invention goes through a chemicalchange, the treatment alters the molecules of the wood to create a newmolecule holding the silicon and the boron compounds within the wood ina matrix defined by the cellulose polymers in the wood and other woodproducts which react with the reactants, as a reacted product or as partof a polymer shield. Unlike currently known technologies, the level ofleeching of the chemical is reduced due to the fact that it isencapsulated within or bound to the wood itself in varying degrees basedon the treatment techniques employed.

Though the molecular change that occurs in the treatment process changessome of the molecular components of the wood, it does not change thestructural character of the wood detrimentally. It hardens the woodthrough the creation of the polymer matrix or shield. Thispolymerization acts as a kind of “plastic”. Depending on formulation itmay increase or decrease the flexibility of the wood while strengtheningthe wood.

All wood can be treated with Applicant's invention. Hardwoods, softwoodsand man-made woods accept the treatment. In current treating processesthere are different treatment levels, treating times and/or chemicaldilution levels that may be employed.

One variation for treatment using Applicant's invention considers thepercentage or amount of liquid within the wood being treated (i.e.“green” vs. “dried”). Less liquid in the wood requires slightly moretime and pressure than wood with a higher presence of liquid.

Because of the molecular change in the wood and the creation of apolymer matrix or shield, wood treated with Applicant's invention isespecially well suited for in-ground and/or underwater use. Applicant'sinvention Treated Products resist the effects of salts, minerals andwater.

Wood treating as known in the current industry follows a long andexpensive path. The path a standard 2″×4″×8″ pine stud would follow fromforest to market in the treating process currently in use as compared tothe process required with Applicant's invention is shown below. Theoverall treatment process utilizing Applicant's invention issignificantly faster and more economical than current treatingprocesses.

Current treating processes necessitate that the wood absorb a great dealof the chemical and the carrier (i.e. water or oil) which significantlyincreases the weight of the wood.

Current Treating Method:

-   -   (a) A tree is felled and hauled to a sawmill;    -   (b) The tree is milled into rough wood pieces slightly larger        than the finished product;    -   (c) The rough wood is kiln dried so as to remove up to 85% of        the moisture content of the “green” wood;    -   (d) The rough, dried board is milled again to trim it to its        finished size;    -   (e) The rough, dried board is treated by immersion into a highly        pressurized (120 psi) cylinder filled with a mixture of water        and a treatment chemical (“CCA”). The treating process typically        lasts from 15-45 minutes;    -   (f) A 2″×4″×8″ pine stud contains approximately 4.5 board feet        of wood. The stud will typically absorb about 1.3 gallons        (approximately 10 pounds) of liquid (chemical and carrier) as a        result of the treat process;    -   (g) The cylinder is drained of chemicals and a vacuum is created        within the cylinder remove excess chemical from the wood and the        boards are removed;    -   (h) The treated board is sent to be kiln-dried;    -   (i) The dried, treated, finished board is shipped.

Contrary, the Process of Applicant's invention with the commonproductive process reveals several differences.

Applicant's invention Treating Method:

-   -   (a) SAME    -   (b) SAME    -   (c) NOT REQUIRED    -   (d) The rough, “green” wood is milled again to trim it to its        finished size.    -   (e) The board is treated by immersion into a slightly        pressurized (15 psi) cylinder filled only with Applicant's        invention. The treating process requires 5-10 minutes;    -   (f) Due to the molecular reaction of Applicant's invention and        the wood's natural liquids, the wood may in certain embodiments        expel liquid while absorbing sodium silicate and borax. The        treated wood weighs approximately as much after treatment as        before;    -   (g) The boards are removed;    -   (h) NOT REQUIRED    -   (i) Since little or no liquid carrier was absorbed by the wood        treated with Applicant's invention, the treated stud weighs only        as much as it did prior to treatment approximately twice as many        studs can be loaded on a single truck cutting transportation        costs.

Some of the unique properties of Applicant's invention include:

-   -   (a) Applicant's invention reacts with the molecules and natural        liquids (mainly water) of wood to draw the reactants from an        organic solvent;    -   (b) Applicant's invention does not require high pressure, to        force chemical into wood added or bent to react the reactants        with the wood;    -   (c) Applicant's invention is able to treat green wood as well as        dried wood;    -   (d) Wood and reacted with applicant's invention is        environmentally clean;    -   (e) Since it becomes “part of” the wood itself the chemical does        not leach out of the wood;    -   (f) Applicant's invention can be used as an after-market        treatment of existing wood;    -   (g) Since little or no carrier is introduced into the wood,        Applicant's invention does not cause swelling of the wood;    -   (h) Applicant's invention can be used in the treatment of OSB        and other man-made wood products; and    -   (i) Applicant's invention may be modified to introduce borax and        sodium silicate into the wood molecules thereby providing        significant water, fire, rot and insect protection.        The Chemistry of Applicant's Invention

The primary method disclosed herein would be to react the celluloseand/or other chemicals within the wood so that all or part of thesereactants are altered chemically.

One of the primary ingredients in wood is cellulose which can bedescribed as a chain of linked glucose units (FIG. 1). Cellulose isgenerally a six carbon and one oxygen chain as shown in FIG. 1. Thereare repeating units (n) so that a consistent structure is indicated.

Cellulose has an average degree of polymerization, dependent on thesource, typically between 3,500 and 12,000 units although a lower degreeof polymerization is found in wood pulp which has been treated.

Historically wood treatment involved covering or submerging the wood orto imbue the voids of the wood with a substance blocking the entry ofelements or to discourage insects from destroying the cellulosecomponent of the wood.

Applicants' invention in one embodiment involves the treatment of thewood with a reactive silicone (preferably) donor which preferably uses acarbon silicon alkoxy groups in conjunction with a pro-catalystcomprising of a carbon silicone halogen combination which replaces someof the molecules or atoms within the cellulose structure with siliconmolecules. As shown in FIGS. 2 and 3, the hydroxyl (OH) groups 29 onsome or all of one or more of the cellulose molecules are reacted withsilicon molecules from the solution of carbon-silicon-alkoxy groups,here tri-methyl chlorosilane. Different diluents may be utilized anddifferent chemicals may be added to change the degree of polymerization,the fire retardant features of the wood, to change the insectresistance, to change the water retention features and the like.

These and other objects and advantages of the invention will becomebetter understood hereinafter from a consideration of the specificationwith reference to the accompanying drawings forming part thereof, and inwhich like numerals correspond to parts throughout the several views ofthe invention.

BRIEF DESCRIPTION OF DRAWINGS

For a further understanding of the nature and objects of the presentinvention, reference should be made to the following detaileddescription taken in conjunction with the accompanying drawings in whichlike parts are given like reference numerals and wherein:

FIGS. 1A, 1B, and 1C are alternate views of the structure of thecellulose of wood.

FIG. 2 is a view of a chemical process for altering the cellulosestructure of wood showing one method of altering the structure of asingle strand of cellulose.

FIG. 3 shows a generic representation of the formula shown in FIG. 2.

FIG. 4 shows one unlikely alternate structural cellulose target.

FIG. 5 shows an alternative unlikely target for the structure of treatedwood.

FIG. 6 shows a representation of cellulose.

FIG. 6 a shows one theoretical model for products by the process taughtherein.

FIG. 6 b shows what the inventor thinks is the more likely productgenerated by the process taught herein.

FIG. 7(a-c) shows the most likely reaction with a silicon donor.

FIG. 8(a-d) shows an alternate embodiment of the invention. FIGS. 8(B1)and (B2) shows alternative intermediary boron molecules which may begenerated in the process.

FIG. 9 shows an alternative mechanism for achieving an alternative tointermediary 8 b.

FIG. 10 shows the production of an intermediary (b) and a possiblereaction using both boron and silicon (a) to guarantee a polymer withsilicon and boron in the modified cellulose structure (c).

FIG. 11 shows a genuine representation of a reagent with cellulose (a).Here the reagent is generically listed as R—Si—(X)₃ where X is an O—Rcompound and R being an alkyl group; halogen, or a hydroxyl group (OH).

FIG. 12 shows a similar reaction to that shown in FIG. 11 with a boronmolecule substituted for the silicon molecule. Alternative embodimentare shown as B1 and B2 where two hydroxyl groups on the cellulose whichare replaced.

FIG. 13 shows a block diagram of a process to treat wood.

FIG. 14 shows a block diagram of a process to form particle board.

FIG. 15 shows the process utilizing a catalyst.

FIG. 16 shows an alternate embodiment of the process of claim 15 wherethe catalyst is acid.

FIG. 17 a-e shows a view of the wood as it's exposed to a catalytic andnon-catalytic reactant of the type taught here.

FIGS. 18-21 show test results of wood exposed to the chemical processtaught herein.

DETAILED DESCRIPTION OF THE INVENTION

The present invention modifies wood by modifying the hydroxyl groups(29) of cellulose. This is, in the preferred embodiment, catalyzed byusing an acid or by creating an acid during a reaction with thecellulose or water within the wood with a pro-catalyst.

As can best be seen by reference to FIGS. 1A-1C cellulose, a mainconstituent of wood, can be drawn as repeating series (n) of celluloseunits having hydroxyl groups shown as 22 in FIGS. 1A and 6A (a modifiedcellulose molecule). FIGS. 1A-1C show typical representations of thesame structure in slightly different formats.

As can be seen by reference to FIG. 2, one method of modifying thestructure of the wood would be to introduce tri-methylchlorosilane(CH₃)₃SiCl (60) to the cellulose molecule to create modified cellulosewith the alkyl silicate bonding across the hydroxyl group(oxygen-silicon covalent bonds) and creating an acid which can furthercatalyze the reaction with non-pro-catalyst as discussed in more detailbelow.

As can be seen by reference to FIG. 3, and as discussed in more detailbelow, the representative molecule shown in FIG. 2 is a derivative of ahydroxyl reaction involving the use of any compounds reactive with thehydroxyl group in the presence of acid or acid by pro-catalyst.

The present invention allows for the creation of a series of moleculesfrom cellulose in preferably wet raw wood products and wood compositeproducts. The process sequentially aligns the molecules as shown in FIG.6 below. In FIG. 3, a generic hydroxyl compound 61 is reacted with ageneric tri-alkyl silicon halide to yield (in the presence of water (64)in the wood) a modified molecule (63) which is more hydrophobic and acid(65) which acid (65) can act as a catalyst to continue the reaction asdescribed in more detail below with reference to FIG. 15.

Silicon or other reactants could, in more violent reactions, be found inother locations in the wood as shown in FIGS. 4 and 5, but these aremore extreme examples and are less likely to occur within the frameworkand are shown as potential by-products which are theoretically unlikelyto occur.

FIG. 6A shows a less likely structure for the molecular bonding wherethe cellulose in the preferred embodiment may contain, by exposure tosilicone and boron reactant molecules and solutions, a limitedreplacement of the hydroxyl groups with boron and silicon becoming apart of the silicon chain. Hence, one product which is claimed by theinvention which is a cellulose chain modified to have a bond betweenhydroxyloxygen atoms (23) boron atoms (24), silicon atoms (25) or otherhydrophobic or anti-degrading elements.

Hydrophobic elements which prevent the reaction include waters andorganic solvents which have a Kow greater than 10. Degrading elements,such as high concentrations of the acids which are generated by thepro-catalysts may be offset by anti-degrading elements such as pHbalancing bases or other chemicals able to eliminate the acidity.

As can be seen by reference to FIG. 6A, these silicon atoms preferablyhave alkyl groups (26) attached to form alkyl silicates. It is taughtthat these alkyl groups may be varied according to the disclosure setforth below or may be replaced with equivalents.

FIG. 6B illustrates the expected end product involving the bondingacross the oxygen (45) hydroxyl groups (29) of the cellulose (37) ofatoms or molecules (here boron or alkyl silicates) with the outervalence shells being competed across oxygen molecules (40) between theatoms or molecules. FIG. 6B also shows how it is possible that thebinding would be less organized than that suggested in FIG. 6A and thatthere may be bonding across more than one hydroxyl group in a singlecellulose molecule within a chain of repeating units (shown again inFIG. 6C as n repeating units. The exact alignment can vary and may bedifferent according to the reactants used. One key fortune of theinvention shown in these Figures is the ability of this process to allowfor proper alignment of individual reactant monomers and trivalent,tetravalent and pentavalent atoms withing the reactants to bond with thewood cellulose structure.

A molecule which can undergo polymerization, thereby contributingconstitutional units (the single trivalent, pentavalent and tetravalentatom constitutional units (e.g. MeCl₃Si-methyltrichlorosilane)) in thisinvention can be referred to as contributing constitutional units orfunctional units or functional groups of the polymer or oligomer (e.g.the cyclic Silanes as described formed after the functional groups arereacted within the wood) to the essential structure of a macromoleculeis a monomer. An oligomer is molecule of intermediate relative molecularmass, the structure of which essentially comprises a small plurality ofunits derived, actually or conceptually, from molecules of lowerrelative molecular mass, i.e. the monomers described herein. Similarly,the polymer definition of a molecule of high relative molecular mass,the structure of which essentially comprises the multiple repetition ofunits derived, actually or conceptually, from molecules of low relativemolecular mass, i.e. the monomers herein described as coming fromindependent trivalent, tetravalent or pentavalent atoms bonded to thedisclosed functional groups or their equivalents.

Also relevant is the polymer properties that in many cases, especiallyfor synthetic polymers, a molecule can be regarded as having a highrelative molecular mass if the addition or removal of one or a few ofthe units has a negligible effect on the molecular properties. Thisstatement fails in the case of certain macromolecules for which theproperties may be critically dependent on fine details of the molecularstructure. If a part or the whole of the molecule has a high relativemolecular mass and essentially comprises the multiple repetition ofunits derived, actually or conceptually, from molecules of low relativemolecular mass, it may be described as either macromolecular orpolymeric, or by polymer used adjectivally.

FIG. 7 shows the suspected chemical process of Applicant's invention. InFIG. 7, methyltrichlorosilane is used as a reactant or pro-catalyst togenerate an acid catalyst (as discussed in more detail below inreference to FIGS. 13 and 14). There are “n/3” molecules of the catalystwhich are drawn out of the hydrophilic organic solvent into the wood toreact with “n” molecules of H₂O present in the wood to yield “n” times 3HCl molecules providing an acid environment for catalyzing the reactionof the silicate with the hydroxyl group. This reaction promotes thetransport of the reactants into the wood and allows for a greaterpenetration of the wood during treatment. Aside from generating the acidenvironment, the pro-catalyst silicate is converted to a hydroxyl form(30) (postulated) which forms a chain as shown at (32) in proximity tothe hydroxyl groups coming off of the cellulose ring units (34) andreacts to form the silicate structure. Which oxygen forms the bindingoxygen (45) may vary without departing from the inventive concept.

FIG. 8 shows one of two ways boron may be introduced into the wood byApplicant's invention and trapped within a matrix formed within thepreferred embodiment. The trapping of boron is particularly helpfulsince it may lead to insect resistance in the end product. In FIG. 8 itcan be seen that a boron compound (41) in the presence of water (fromthe wood) forms a boron hydroxyl molecule (42) which (in the presence ofacid) may polymerize much as the silicate in FIG. 7 to form a boronhydroxyl chain (43) which in the presence of the cellulose binds to formchains (44) in the cellulose matrix. Alternate Borates as shown at (42)or as shown as B1 and B2 may be formed as intermediary or final productswhich can be trapped in the matrix formed by the silicates shown in FIG.7 where boron and silicone products are used together or in the matrixpostulated as formed by the boron compounds as shown in FIG. 8. Sincewater cannot get through, the atoms of free borates (borates not forminga part of the matrix) and other additives are effectively trapped withinthe wood by this treatment.

Bonding may be accomplished using trivalent atoms for bonding althoughthis reaction as shown in FIG. 8 only in the presence of a strong acidor pro-catalyst generating a strong acid.

The process works effectively in the presence of hydrochloric acid orother acid having a pKa of less than 2.5. Boric acid, for example, whichmay form as in intermediary, would not drive the reaction shown in FIG.8. The use of pro-catalysts is described later herein, but it may beseen by reference to FIG. 7 where the tri-chlorosilane, as pro-catalyst,yields 3 HCl which acid would drive the reaction. The acid may or maynot be referred to as a catalyst. This is also true of the reactionshown in FIGS. 9 and 10 where the trichlorosilane drives the reactionthrough the production of hydrochloric acid during the solvation of thereactants. While a pKa below 2.5 is preferred, the reaction can bedriven by an acid catalyst with a pKa for acid catalysts below 4.00 andpKb for base catalysts above 9.00.

FIG. 10 shows Si(OH)₃CH₃ and B(OH)₃ from the solvent drawn into andreacted with the wood cellulose using a catalyst which is introducedinto the wood as a pro-catalyst (FIG. 7) or otherwise. One other waywould be inject a solution with a weak acid concentration (0.1%-0.5%) ofstrong acid into the wood, but this would be different from the simpletransport of reactants where the reactants (trivalent, tetravalent, andpentavalent atoms with an alkoxy component or as pro-catalyst with ahalogen component) are drawn from the organic solvent into the wood downconcentration gradients and which react exothermicly.

FIG. 10 shows a mechanism for the combination of silicates and boronmolecules to form intermediary chains (50) comprised of silicone andboron which in proximity to cellulose (37) forms the modifiedcombination cellulose and boron and silicone molecules (51) which arealso those shown in FIG. 6B. While boron and silicon with hydroxy groupsare shown, combinations of alkoxy and hydroxy pentavalent, trivalent,and tetravalent atoms with combinations of acids and pro-catalysts.

FIG. 11 shows an alternate mechanism for the combination of siliconreagents with cellulose. In FIG. 11 it can be seen that the cellulose isplaced in proximity (by way of a carrier solution of the type describedin more detail below) with a group R′—Si(X)₃ (52) where R′ is an alkylor it's equivalent as discussed in more detail below and X is an ORgroup (R being a alkyl group from the same generic group as R′) or ahalogen or a hydroxyl group OH or combinations thereof. This reactionshown in step B1 or B2 yields an intermediary (53) or (54) or bothintermediaries. These then, in the presence of an acid or acidgenerated, for example, by the trimethyl chloro silane or otherpro-catalyst, yields a more complex molecule where the silicate iscombined along the carbon atoms of the cellulose as opposed to thehydroxyl groups as shown at B3.

FIG. 12 shows the embodiment of FIG. 12 where boron compounds (55) aresubstituted for the silicates of FIG. 11 to yield the end products shownin steps B or C of FIG. 12.

In order to allow for use of more common reactants, it is envisioned, asshown in FIGS. 15 and 16, that a catalyst for the reaction could beprovided by acids or molecules yielding acids. In this preferredembodiment, the process includes the steps of:

-   -   1) Preparing a hydrophilic organic solvent, for example ethyl        alcohol,    -   2) Adding a silicone donor, such as a one to eight carbon        alkyloxy group (methoxy, octyloxy, etc.)    -   3) Adding a strong acid (hydrochloric, phosphoric or sulfuric        acid) directly or, preferably, by way of a pro-catalyst yielding        the acid in solution by reaction with the water in the wood such        as methyl trichloro silane (CH₃SiCl₃). In the preferred        embodiment this is preferably an acid solution generated from        the pro-catalyst in a concentration of 0.5%, but may range from        about 5% to 0.1%. It may also be outside this range with less        certain results since the acidity in the wood is not desirable        for most uses.    -   4) Exposing the solution prepared in steps 1-3 to cellulose to        allow binding as shown with or without time and pressure        restrictions to limit the extent of treatment.

The acid serves, when in contact with the water in the wood, to yieldROH and RSi(OH)₃ compounds. The RSi(OH)₃ reacts as discussed above withthe cellulose to bind in place of one or more of the hydroxyl groups ofthe cellulose to form the hydrophobic barrier. Alternatively, theprotonated silicon donor (protonation by acid generated in situ with thepro-catalyst) reacts directly with the hydroxyl groups of wood molecules(e.g. cellulose) to form covalent oxygen-silicon bonds.

The compound used as a reactant may be an alkoxy group having theformula R—Si(OCH₃)₃ with the exact structure of the alkoxy part (OCH₃)being subject to any variation within this group of chemicals whichperforms the desired function shown in the drawings. Free boroncompounds in this formulation are expected to have peak efficiency under2% since the boron tends to counteract the hydrophobic properties of thesilicates when the boron is not bound to the cellulose structure. Thisis an acceptable range since wood treatment generally requires 0.5%treatment with boron to be effective.

Boron may be added as boric acid to the formula effectively in the rangeof about 0.5 to 5% and is trapped in the silicone matrix. Alternatively,a reactive boron reagent of the type discussed above may be used to forma boron matrix such as that disclosed in FIG. 10 when used inconjunction with a silicon donor and a reactive silicate pro-catalystother trivalent, tetravalent or pentavalent pro-catalyst structures.Other molecules drawn from the solvent and producing a catalyst in thewood may be used.

In this structure, the acid is in very low concentration (in the case ofmethyl trichloro silane approximately 0.5%) to the silicone main donor,in this example octyltrimethoxysilane (MTS). This is significant formany reasons, not the least of which is the limitation of the acidity ofthe end products, the minimization of expensive reactants, the safety ofthe solution and the lack of toxic emissions.

In one example, that of FIG. 15, the formula is alkyltrialkoxysilaneplus alcohol as the carrier plus an acid catalyst plus boric acid as atreatment.

The second example (FIG. 16) might employ the use of B(OCH₃)₃ (trimethylborane) at any percentage depending on the amount of boron desired. Inthis example the importance of another acid would be to catalyze thereaction.

The acid catalyst could even be in the range of about 0.01 to 10%. The10% figure is pushing the reaction as a 10% acid would not affect anenvironmental change 0.01-4.9% is considered a better range. A basecatalyst may also be employed, but is less effectively within the samerange. Examples are metal alkoxides [eg. sodium methoxide] ammonia,organic bases [eg. triethylamine].

It has been determined that to drive the reaction without an outsideenergy source in the embodiments tested that the acid should have a pKaof about 2.5 or less.

Methyltrichlorosilane (MTS) is a compound which in this processfunctions as an acid catalyst on contact with wood cellulose or moisturewithin the wood. This could be substituted with other alkyl or arylsilicone halides to generate the acid catalyst in situ in a range of0.01-10%. It is theorized that this produces hydrochloric acid whichwill drive the reaction consistent with the limitations set forthhereinabove. In the method shown in FIG. 10, the wood may be exposed toa solution tetrahydrofuran (90%) having 1.0% percent borax as an insectrepellant and 9.0% methyltrichlorosilane (Cl₃SiCH₃ or MeCl3Si). As shownin FIG. 10, the MeCl3Si and boron has hydrolyzed to produce MSi(OH)₃ andB(OH)₃ as well as hydrophillic acid as catalyst.

As shown in FIG. 13, this solution may be enclosed with the wood. Heatfrom the reaction will add pressure which will increase the saturation.The release of pressure and heat will indicate a completed reaction.

Alternatively, the reaction time and pressure may be controlled so thatless of the interior of the wood is affected to provide a surfacetreatment so that boron or other additives will be less completelytrapped within the wood product.

A modified process of spraying or brushing may be utilized. This wouldbe useful on existing structures or living trees. It will also be usefulwhenever immersion is not possible.

Specific embodiments taught herein use boron or other metallic ormetalloid atoms such as boron, aluminum or metals such as copper, orcompounds such as aluminum acetate containing those atoms that, inconjunction with a carrier, and preferably a reactive silicate of thetype described herein provide additional protection within theartificially fossilized wooden products.

Borax is an example of a boron salt which may be used in conjunctionwith the process. In order to incorporate Boron, Borax or BoronAnhydride may be used. In addition Boric Acid or trimethyl borate, aboron halide such as boron triflouride or boron trichloride with a saltcan be used for different effects.

The steps in processing the wood would be to prepare the solution, putthe wood in solution and optionally allow the combination of the woodand solution to be sealed so that the heat and pressure generated by thereaction, for example, between the methyl trichlorosilane could build.In the sealed embodiment, when the pressure drops, indicating that theheat generated by the reaction is ended or after a set period time ifthe wood is not to be fully treated, then the wood would be taken out ofthe solution.

An alternative step in this inventive process is to treat composite woodwhich has glues which favorably interact or react with silicon (or othersolute compounds) in order to strengthen the bonding within the glue. Itis noted that certain solvents will not affect certain glues and aproper combination of glue and solvent and silicate (reactant or donor)is necessary.

This can be found in what is commonly known as press board whichutilizes a combining glue. The wood, even in these compressed and gluedproducts, is treatable. The silicon or other atoms in the solutecompound may participate to strengthen the bonds in the glue where aproper combination is utilized.

This treatment can be accomplished with other components of wood such aslignin, carbohydrates and polysaccharides in order to accomplish similarresults. Cellulose is preferred since it is such a prevalent part of thecell structure. Also, it can provide a template for alignment of theshield.

Other techniques, disclosed in the specification incorporate the use ofultrasound in order to increase the ability of the wood to carry thereactive compound of the type described herein or even when using atraditional treatment mechanism (FIG. 13).

Silicon donors include methyltrichlorosilane, triethoxyoctylsilane,octeotrimethylsilane, chlorotrimethylsilane and phenyl trichlorosilane.

The basic chemical process includes reacting the silicon and/or borondonors (or their equivalents) with water molecules from water in thewood. In the case of boron, that would yield boric acid plus water plusH₂B₄O₇ using of trimethyl borate or a different alkyl borate. (FIGS. 7and 8).

These would each react with one of the OH or hydroxyl groups of thecellulose in the presence of a strong acid derived from the pr-catalystincluded in the formula.

The silicon would bond at the same location as the hydroxyl group. Ifboron and silicon are used together, a certain proportion of thehydroxyl groups would be replaced with the boron compound and a certainnumber will bond with a silicon compound and in some cases there couldbe an exchange.

The basic structure of the molecules used in the process describedherein include:R-Xa-Xb₃orR₃-Xa-XborR²-Xa-Xb₂orR₁-Xa-Xb₂orR₂-Xa-Xb₁orR₄-XborR₃-Xb

R is a straight chain or branched chain alkyl group, aryl or benzylgroup, Xa is a trivalent, tetravalent or pentavalent atom and Xb is ahalogen (halogens including fluorine, chlorine, bromine, etc.) atomhaving valence electron and which may react or their equivalent.

Silicon procatalyst donors might be shown with the general formulaR—Si(X₃) This silicon donor can be represented by the general formulawhere Xb₃ is a halogen such as chlorine, bromine, iodine.

Instead of halogens, Xb could be an alkoxy group (such as methoxy,ethoxy, propoxy, butoxy or an alkoxy group with the number of carbonranging from 3 to 20 in a straight chain or a branched chainconfiguration. Larger chains cause interference problems with thereactions). The Xb₃ may also be a phenoxy group, a benzyloxy group or anaryloxy group in which the aromatic ring is replaced with a polycyclicaromatic ring. These would not produce acids.

Silicon could be replaced with a group 4 atom such as Ge, Tin or lead.Lead, for example, may be useful in the construction of nuclear plants.

The mixture of the boron and silicon donors with solvents will determinethe type and extent of bonding.

While boron and silicon are used to this example, titanium would workand so would many trivalent, tetravalent, or pentavalent atoms. In otherwords 3, 4 or 5 valence state atoms (i.e. atoms from groups 3, 4 or 5 ofthe periodic table) would work in the bonding process. Examples ofsubstitutes for boron include Aluminum, Galium, Indium or thalium (Tl),by way of example.

Reagents: Boron and Silicon and related reagents include:

-   a) Boron oxide (B2O₃) like other metals having a 3, 4 or 5 valence    outer shell could react with moisture and water within the wood or    wood products to generate Boric Acid that could be entrapped within    the polymer matrix or shield when used as a mixture with silicon    donors or may react with acid or acid pro-catalysts as shown above.    -   b) Chlorotrimethylsilane could be pro-cataylst and reactant    -   c) phenyltrimethoxysilane could act as a silicone donor, but        requires an acid (or base equivalent) to react.    -   d) Triphenylsilylchloride could act as a silicone donor, but        requires an acid (or base equivalent) to react.    -   e) Propyltrichlorosilane could act as a silicone donor, but        requires an acid (or base equivalent) to react.    -   f) Propyltriethoxysilane could act as a silicone donor, but        requires an acid (or base equivalent) to react.    -   g) Hexamethyldisilanzane could act as a silicone donor, but        requires an acid (or base equivalent) to react.    -   h) Titanium tetrabutoxide [TBT] is an example of a tetravalent        metal in place of silicon. Other atoms could be used.    -   i) Triethylorthosilicate could act as a silicone donor.    -   j) OCTEO-S [n-octyltriethoxysilane, TECH] is a silicone donor.    -   k) Octyltriethoxysilane could also act as a silicon donor.    -   l) Trimethylborate [TMB]. Reacts with water/mixture within wood        to undergo partial or full hydrolysis to polyborates or boric        acid respectively. (See FIGS. 8, 9 and 10). It could react after        partial hydrolysis with methyltrihydroxysilane to form mixed        boron and silicon polymers as shown. It can directly react with        cellulose in the presence of acid catalyst generated from        pro-catalyst to permanently from an oxygen-boron covalent bond.    -   m) Tri-ethylborate is a reactive alternative which shows the use        of an ethyl group in place of a methyl group to produce a        similar result with a larger carbon chain. Large carbon chains        or ring compounds may also be used as long as the carbon groups        are not so large as to interfere with the reaction.    -   n) Boron halides generally are workable, such as        borontrichloride, borontribromide and borontrifluoride. These        are highly reactive compounds which directly react with the        hydroxyl groups of wood cellulose or other compounds of wood to        form respective borates with the elimination of acid halides.    -   o) A 0.5 percent solution if boric acid in acetone with an        appropriate amount of TMB can be used for a more stable        formulation with a silicon donor such as MTS        (Methyltrichlorosilane).    -   p) Methyltrichlorosilane [MTS] is another procatalyst. This        reagent in THF as a carrier is one of the initial formulations.

FIG. 7 shows the hydrolysis of MTS to methyltrihydroxysilane within thewood (postulated) and its subsequent conversion to a polysiloxane thatreacts with the hydroxyl groups of wood cellulose forming the polymermatrix or shield.

If, in a reaction, hydrochloric acid is released, the acid wouldpreferably be diluted, degraded (neutralized), or otherwise removedduring or after the treatment process to prevent the degradation of thewood or irritation caused by the slow release of this acid to theenvironment. It could, for example, be converted to environmentally safesubstances. Salts may be produced.

This reaction may be shown as:

R—Si—X₃ (here (CH₃)—Si—Cl₃) in a solvent to yield—R—Si—(OH)₃ (Step A)which would subsequently react with cellulose (Step B) to form themodified cellulose chain as shown in FIG. 6 (Step C) plus water.

Diatimatious earth, sodium silicates, or other boron or silicon saltsmay be used as a source of donor atoms. These may be mixed to provideintermediaries in solution which would, working together, achieve thedesired end product in the wood. Examples of products having thesequalities include boric acid, trimethyl (trialkyl) borate, Boron Halides(BF₃, BCl₃, for example), and Boric Anhydride (boron oxide).

Solvent: The solvent can vary tremendously also although it ispreferably a non-water based solvent so as not to cause a reaction or anorganic solvent with a minimal water component. It would typically bestructured so as not to effect the glue or other properties of woodcomposites when treating wood composites. THF (Tetrahydrofuron),alcohols, or acetone are exemplary solvents.

(Acetone) is also a good carrier for non-glue wood composites.

(THF(Tetrahydrofuran)) works well with glues used in wood.

Polydimethylsiloxane maybe used as an additive especially with boroncompounds to increase the silicone content.

Alcohols, such as methanol or ethanol work well.

Water is also a solvent present in some cases given its trace presencein many solvents. Water may be used with this formulation as analternative to part of the organic solvents in certain formulations.Water is not the most preferred compound because it would compete withwater in the wood unless a slower reaction was desired.

The various silicon-boron combinations, with or without the additives,will work on all wood, treated wood and wood products, with varyingefficiencies and results. Individual variations in results may occurbased upon the nature of the solvents used to prepare the formula andwith the kind of sample of the wood to be treated.

Solvents and chemicals are selected for compatibility with the type ofmaterial or wood being treated. For example, the acetone pro-catalyst,non-catalyst reactant formula may be optimal for soft wood, whereas theacetonitrile solvent formula may work better for hard wood.

Likewise the non-acetone based formula may be the preferred embodimentfor treatment of Particle Board, OSB or Chip Board where the glue isdissolved by acetone. The alcohol based formula may be better forsouthern pine.

In some cases the solvent and additive may be reacted to form a gel andin other cases it might be useful to agitate the solution in order toprevent gel formation.

The proportion of chemicals results in different finishes and featuresand the solvents can also contribute to the variety of productout-comes.

Other solvents include any water compatible organic solvents, such asdioxane. One of the key elements of the solvents in most applicationswould be that it would have a boiling point under a 100 degreesCentigrade.

It is believed that borax, sodium silicate and other additives can betrapped inside the polymer shield formed by the reaction.

The current Applicant's invention formula incorporating thecarbon-silicon-halogen reagent, a boron donor, borax, sodium silicate,metal or metalloid catalysts or enhancers with THF or it's equivalentsas the solvent.

The applicant's invention allows for different stabilizers andenhancers.

One example is the use of chemical additives as enhances to retard firessuch as phosphorous compounds.

Catalysts [Acids and products yielding acids in solution] can be used toenhance the process as shown and described above in reference to FIGS.15 and 16. Indeed, this type reactant is necessary to drive the reactionin the preferred embodiment.

Another method of enhancing the process is to provide that it be done inan enclosure to allow the chemical reaction to build pressure. Pressuremay be induced by external factors to the chemical reaction such as theuse of ultrasound to speed up the process by aligning the moleculeswithin the wood (whether cellulose, lignin or other molecules alone orin groups).

Other pre-treatment steps include the infusion of moisture in the woodbefore or during treatment, the use of wood closer to the productionstage (i.e. greener wood), or putting other solvents or additives withthe water within the wood prior to treatment with the reactant chemicalsin order to provide carrier or additives chemicals within the wood toenhance the treatment. Water might be mixed with wood composites inorder to help the process along.

Donors (of boron or silicon for example) may be infused within the woodor composite prior to the addition of the solvent or acid on silicatecatalyst. This would be particularly simplified where wood composites(fiberboard for example) were being manufactured prior to being treatedin the process steps.

The R group in the above silicon (or other trivalent, pentavalent ortetravalent atom) donor is an alkyl group ranging in a carbon chainlength of 1-20 units in a straight chain or branched chainconfiguration. All these reagents are capable of undergoing the similartransformation as depicted in FIG. 7, FIG. 14 or FIG. 15. Thenon-halogen substituted silicon reagents (alkoxy and hydroxy) in thisgeneral formula react only slowly and the completion of the reactionwould require a longer time, under ordinary conditions. However thisprocess could be enhanced by the inclusion of acid or base catalysts tothe silicon reagents, as shown in FIGS. 14 and 15. These catalysts mayinclude, but are not limited to, a metal alkoxide or an acid such asmeta-phosphoric acid.

In the above general formula Silicon (Si) can be substituted, forexample, with Titanium (Ti) and all other factors may remain the same. Atypical example would be Tetramethyltitanate. A general representationof the formula would be Ti[R]₄ where R=a halogen, an alkoxy group, aphenoxy group or a benzyloxy group as defined above for the silicondonor.

Hydrophobic Reagents include gasoline and tolulene.

The following silicon reagents can also react with the hydroxyl groupsof wood components to render wood hydrophobic, insect and fireresistant:

(1) Dichlorodimethylsilane represented by the general formula:[R]₂Si(X)₂; where R is an alkyl group ranging in carbon chain length of1-20 units as a straight chain or as a branched chain, or a phenyl groupor a benzyl group and X=a halogen, an alkoxy, aryloxy or benzyloxy asdefined above. Another common example is dichlorodiphenylsilane.

(2) Chlorotrimethylsilane represented by the general formula [R]₃Si—Xwhere R is an alkyl group ranging in carbon chain length of 1-20 unitsas a straight chain or a branched chain and X which is a halogen analkoxy, aryloxy or benzyloy as designed above. Another common example isChlorotriphenylsilane.

(3) Hexamethydisilazane: This compound will form a trimethylsilylderivative of the hydroxyl groups of the components of wood or woodproducts with the evolution of nitrogen in combination with anappropriate catalyst. The catalyst may be phosphoric acid that by itselfmay render the wood fire resistant.

(4) Octyltriethoxysilane [OTS]. This is an excellent reagent that wouldfunction in a neutral environment. The reagent is cost-effective andenvironmentally clean. Possible improvements to speed up the reactionwith the addition of catalysts [metaphoshoric acid for example] couldalso render fire proofing. Another common example ispropyltriethoxysilane.

Phosphorous Reagents

Phosphorous reagents can also be used to modify the hydroxyl groups ofwood components to make the wood fire and insect resistant. Commonreagents that can be used for this purpose are:

(1) Triethylphosphate: Here phosphorous is in the pentavalent state andthe trimethoxy groups are prone to hydrolysis by moisture/water withinthe wood and generate phosphoric acid or polyphosphoric acid which is afire retardant. The hydroxyl groups of the cellulose or other woodcomponents may directly react with triethylphosphate displacing one ormore of the methoxy groups with the formation of a chemical bond betweenthe phosphorous and the oxygen atoms of one or more of the hydroxylgroups. Another common example is trimethylphosphate.

(2) Triethylphosphite: Here phosphorous is in the trivalent state as intrimethylborate [TMB] and the mechanism of reaction with wood or woodcomponents are identical to those of TMB as described above. As is thecase with TMB there are two possibilities. Triethylphosphite can reactwith moisture (water) in the wood or wood components to producephosphorous acid or polyphosphorous acid within the wood to make it fireand insect resistant. When used in combination with a silicon reagentthis combination would trap the phosphorous acid trapped. Alternatelytriethylphosphite can react with one or more hydroxyl groups of woodcellulose or other components of wood to form permanent chemical bondsto render wood fire and insect resistant. Other common reagents aretrimethylphosphite or triphenylphosphite.

Copper compounds may be used in place of or in conjunction with siliconand boron within the process embodied herein. No chemical processnecessarily results in a single outcome. FIG. 6-B shows an approximationof the most likely end structure for cellulose without a completereplacement of hydroxyl atoms in the chain when treated with a mixtureof silicon and boron under the process steps taught hereunder.

FIG. 6A shows an alternative structural outcome.

FIG. 8 shows the reaction postulated for a boron donor. The corrugateddouble line 1 represents the cellulose polymer while the cellulose OHgroups are non-remarkable, hydroxyl groups coming off from individualcellulose molecules within the polymer as a result of the reaction.

FIG. 8 shows where B(OCH₃)₃ (A) is converted to an intermediary B (OH)₃(B) which then reacts with the hydroxyl groups (C) to yield a polymer ofBoron and Cellulose polymer in the presence of a strong acid.

FIGS. 8B1 and B2 show alternative intermediary boron molecules which maybe utilized in this process.

As can be seen by reference to FIG. 13, the process of treating wood maybe described as introducing a wood product (3) into a chamber (12) whichopens at entry (9). The entry (9) is then closed and if desired anelectromagnetic field is introduced to expedite the reaction using fieldgenerators (11) which may be magnets or ultrasound generators to obtaindesired atomic alignment to enhance or restrict the reaction. In thepreferred embodiment ultrasound is used to align and open the partialpassages of the wood to enhance penetration.

This field may be maintained by the process or it may be begun andstopped repeatedly or terminated after a certain time to get the desiredpenetration or to limit the treatment area to the surface of the wood byclosing the natural wood passages. At this time, or before, one or morereactants may be introduced into the chamber (12). Thereafter the entry(9) is closed unit other reactants are added or removed. The reactantsmaybe introduced or removed through a chemical opening (4) in thecontainer which may be sealed by a valve (7). The valve may include atemperature or pressure monitor to determine when the reaction iscomplete or when it has reached a certain level. The chamber may bevented.

At any point the reagents may be drained through a valve in a drain (5)and other chemicals, such as an acid neutralizing agent, may be added towash or treat the wood.

Thereafter the wood my be removed from the entry (9) or an appropriateexit (10) so that one piece of wood may be used to push the other out ina continuous process.

FIG. 14 show how particles of wood (13) may be turned into particleboard utilizing the process through the steps of [1] combining theparticles (13) with a glue (14) and, optionally, [2] one of the reagents(15) (such as borax) in a chamber (18) in the bottom (19) of a press.[3] Before, after and during the compression process when the top (17)of the chamber presses on the mixture of glue, wood and reagent, [4] asolvent (16) which may include all or one of the reactant solutes may beintroduced through a passage (20) in the chamber to initiate thereaction. A pressure release valve (21) may be used to allow gases andpressure to escape this process.

The process of locking in entrapping, or reacting beneficial atoms ormolecules within the wood structure comprises the steps of:

-   -   Selecting an additive which may enhance a desired property from        the group of properties comprising:        -   (a) Fire resistant,        -   (b) Insect resistant,        -   (c) Moisture resistant,        -   (d) Modified by color or stain (such as by iodine which may            also be used in radioactive form for determining            penetration),        -   (e) having better glue attachment qualities (silicon            typically reinforces the formaldehyde and resin type glues            used for wood),        -   (f) having better insulation qualities (sulfates, such as            carbon di-sulfate workwell), and        -   (g) to change the chemical structure of cellulose or some            other chemical within the wood to change specific            characteristics to the wood.    -   (2) Adding the additive to the wood by:        -   (a) mixing particles of wood with the additives and forming            a wood composite;        -   (b) dissolving the additive and flowing the additive into            the wood or;        -   (c) pressing the additive with the wood in a gas or solid            phase; and        -   (d) reformulating the wood cellulose polymer to create a            partial or full barrier to leaching.

An optional step may be to enhance absorption of the additive orreformulating chemicals using (i) alignment and/or opening of wood poresusing ultrasound, electromagnetic fields, heat, heat with steam and thelike.

Because wood cellulose defines a specific matrix or structure (as shownin FIG. 1), oligomers would have a difficult time forming alignedintermediaries such as those shown in FIG. 8 c or 10 b where thereactant atoms (here silicon and boron) are aligned to covalently bondtogether and to the wood cellulose to form the desired shielding.

In order to avoid the creation of oligomers which would preventalignment and the desired reaction within the wood, the amount ofnon-hydrophilic (including hydrophobic) solvents and water, must belimited to still have reaction work. Also, the non-catalytic reagentratio to catalytic reagent must be controlled to prevent damage to thewood.

Therefore, to carry out a reaction which is commercially viable, thepreferred ranges for reactants and non-reactants in the solution appliedto wood where a catalyst or pro-catalyst (an acid or an acid producingmolecule) is used to drive the reaction could be expressed in the ratiosor percentages as set forth below.

(1) The range of acid or procatalyst is in the range of about 0.1-10%.Practically speaking, to protect the wood, this would be from about 0.1to 4.9%. For purposes of these limitations, the only acids which wouldwork efficiently would be those with a pKa of about 2.5 or less. Thiswould include acids like Hydrochloric and Phosphoric acid as shown inthe examples. Pro-catalysts would be those chemicals yielding an acidwhen exposed to the moisture in the wood or when exposed to the woodhydroxyl groups. Tri-chlorosilane is an example. A lower concentrationas low as 0.01% would work slowly; but, since it acts as a catalyst,would still work.

(2) The range of non-catalytic reagent (NCR) would be in the range of0-65%. Non-catalytic reagent would be reagent which would not reactunless in the presence of a pro-catalyst or appropriate acid. Examplesof non-catalytic reagents would include hydroxyl and alkoxy bonded totrivalent, pentavalent and tetravalent atoms without halogens bonded toalkyl or aryl groups. The concentration of NCR to pro-catalyst is usedto control the cost, acidity and efficiency if the reaction.

From a comparison of the above referenced percentages, it can be seenthat the range of acid or pro-catalyst to non-catalytic reagent would bepreferably in the range of 1:6 or less (one molecule of pro-catalyst forevery molecule of non-catalytic reagent). Preferably the catalyst wouldbe in the range of 5% or less of the non-catalytic reagent. For example,if the catalytic reagent was 50% of the total solution, then thepro-catalyst would preferably be less than 2.5% of the total solution.

(3) The amount of water added to the solution would slow down or degradethe reaction. In order to control this, the practical range would befrom 0-0.5%. Using agitation to prevent the formation of oligomers andnon-reactive components would allow water concentrations as high as8.0%. Another useful limitation would be to maintain the waterconcentration 2.0% below the concentration of the pro-catalyst and NCR.

(4) Similar to water, the concentration on non-hydrophilic organicsolvents or even non-organic solvents (such as water) may occur insimilar ratios to the solution. Operational ranges for non-hydrophilicorganic solvents could range from 0-20%, although a 10% or less rangewould be more practical.

The use of hydrophilic organic solvents is critical to maintainingreactivity in most situations where this reaction could be run and whilea concentration as low as 10% might yield a reaction which could work, amore practical range would be in the range of 99.9%-30% of the totalsolution. If a competing reaction was present, such as is present wherewater is used, the solution would have to be 50% more hydrophilicorganic solvent then water concentration to remain commercially viable.

Except where used to slow the reaction, the non-hydrophilic organicsolvents or non-organic solvents (such as water) would essentially beimpurities adding nothing to the beneficial aspects of the reactionexcept where they could enhance the processes described herein.

5) Since some oligomerization may occur and still allow the reaction togo forward, it is important to view the invention as one wherein thereis a solute compound having a functional group which includes (i) anatom selected from the group consisting of trivalent, tetravalent andpentavalent atoms, wherein said atom is bonded to

-   -   (A) a halogen atom or    -   (B) a functional group selected from the group        consisting of a hydroxyl group, alkoxy group, phenoxy group,        benzyloxy group and an aryloxy group having a polycyclic        aromatic ring, in the form of a monomer or unstable (transient)        oligomer. Since trace amounts of oligomer may occur, the        invention can be safely described where the monomer, as a        percent of total solution, is over 5%. To be practical, the        monomer should be at least 10% of the total solution. This        monomer is the reactive component of the solution.

The instant patent technology differs entirely from the prior arttechnology with respect to the composition in several particulars.

1. Chemical composition of the treatment formula is chemically welldefined and identified.

2. The composition does not make use of aqueous solutions. An anhydrousorganic solvent is required for the composition.

3. The composition must have a halogenated silane component as apro-catalyst or a comparable substitute while acids with a Pka of 2.5 orless will work. The effective use of pro-catalyst allows the reactionthrough the production of acid in the wood. Mixing the acid into thesolution prior to putting the chemical into the wood can work, but it ispreferably done using lower concentrations with pro-catalysts.

4. The formula or the solute compound is sufficiently small andorganized so that it enters wood without prior conditioning and alignswith the wood cellulose without the need for excess energy to disruptthe composition of the solute compound in the wood or during treatment.Wood need only be dipped, brushed or sprayed with the formula toaccomplish the desired result.

5. The composition instantly reacts with wood hydroxyl groups on contactand activates the accompanying reagents to form silicon-oxygen covalentbonds not only on the surface but also within the wood, probably forming7-12 member cyclic silane rings (FIG. 17).

6. Applicant's inventive composition requires no prior drying of wood orno drying of wood after treatment and no curing of wood to be effective.

7. The instant formula are unique with respect to defined and pureingredients. The formula may employ a halogenated silane (or otherpro-catalyst generating the appropriate acid within the wood) or it'sequivalent and a non-aqueous organic solvent to be effective.

8. The present formulation also has definite and commerciallysignificant advantages with respect to the use of pure and well definedcompositions. The reactants penetrate wood without mechanical assistance(such as application of vacuum, or heat pressure). Stable silicon andboron bonds to wood that are not leached out are formed in a simpletreatment. Non-water based formulations are used. Water is notrecommended in the compositions and a non-aqueous organic carrier isused. A halogenated silicon [eg. Methyltrichlorosilane] is used as thereactive reagent (pro-catalyst). The reaction of methyltrichlorosilaneto wood hydroxyl groups forms spontaneous permanent bonds wood. It mustbe noted that only after this initial spontaneous exothermic reactiongenerating the energy with which to carry the reaction to the point ofcreating a polymer out of the cellulose.

The present invention includes the use of un-oxygenated silane chemicalswhich are applied to the wood and, utilizing a catalyst in the form ofacid or a reacted solute such as a halogenated compound such asmethyltrichlorosilane that in the wood cellulose matrix are reacted inorder to get the intermediary oxygenated silane which then immediatelyreact with the hydroxyl groups in the cellulose in order to polymerizethe oxygen and silicon atoms in order to form chains directly on thewood cellulose catalyzed by the acid formed by water in the wood and thehalogen. The dramatic and non-obvious result is that instead of havingto utilize energy in order to generate the reaction, the reaction itselfis self-propagating and will generate heat and pressure until the entirewood is treated or until the silane reagent is used up forming aprotective barrier on every side of the wood cellulose chains.

An added benefit is, instead of requiring that the oxygenated solute bepushed into the wood under pressure leading to imperfect saturation andhigh cost, the reaction pulls in the unoxygenated silane as fuel for thechemical reaction so that penetration may be obtained at a much deeperlevel.

One reason for using organic solvents is in order to prevent theoxygenation of the silane until they come in contact with the waterwithin the wood. One limitation would be to have at least 50%unoxygenated silane to prevent waste.

Methyltrichlorosilane is not the predominant reagent in the mosteffective embodiments, but is an activator used in catalytic amounts toinitiate the reaction of a nonactivators such as methyltrimethoxysilanewhich is the primary reagent that forms the vast majority of covalentlinkage to wood molecules having hydroxyl groups [cellulose, ligninetc].

The solvents, in the preferred embodiment, are non-reactive hydrophilicsolvents to allow penetration of reactive reagents [a mixture ofmethyltrichlorosilane and trimethyl borate, for example] andnon-reactive alkoxy silanes to deep within or interior of both wet anddry wood.

A plurality of Applicant's reactive molecules may enter to the woodcellulose from a solution as shown in FIG. 17A. Here the solution is analcohol 72 solvated solution, although there may be trace amounts ofwater 71 and other organic solvents 70. A pro-catalyst 27 (MeSiCl3 here)and a silicone donor 73 (MeSi(OCH3)3 here) are used to prevent thepro-catalyst 27 from adding too much acidity to the wood. The use ofhydrophillic organic solvents and monomers allows the reaction to beginand proceed by simple diffusion of the solvents and reactants into thewood.

One of the pro-catalyst monomers 30 has reacted with water in the woodto form the catalytic acid 65 (HCl) as also shown in FIG. 7.

FIG. 17 b shows where the acid 65 is catalysing the reaction with anon-pro-catalyst silicone donor 73.

Next, this process continues so that a plurality of reactive moleculesares chemically linked to at least one second reactive molecule so as toform a matrix of cross linked reactive molecules one reactive moleculelinked to the wood as shown in FIG. 18C and also linked to at least oneother reactive molecule linked to the wood FIG. 17 d to form a crosslinking of reactive molecules and wood FIG. 17 d. Within or betweenthese modified cellulose chains, borates 42 and other additives may betrapped as shown in FIG. 17 e.

The result is a plurality of reactive molecules having a link to thewood cellulose and wherein at least one first reactive molecule ischemically linked to at least one second reactive molecule so as tocross-link the plurality of reactive molecules to the wood cellulosethrough one or more of the hydroxyl groups on the wood cellulose. Thecompounds are covalently bonded through reaction with one or morehydroxyl groups of the wood cellulose.

At least one first reactive molecule is chemically linked to at leastone second reactive molecule so as to cross-link the plurality ofreactive molecules to the wood cellulose through one or more of thehydroxyl groups on the wood cellulose.

The solution contains a hydrophilic organic solvent and a plurality ofmolecules having at least one first molecule and at least one secondmolecule selected from R-Xa-Xb₃, R₃-Xa-Xb, R2 Xa Xb2, R2 Xa Xb, R4Xa,R3Xa or R Xa Xb₂, wherein R is an alkyl group, Xa is a trivalent,tetravalent or pentavalent atom, and Xb is a halogen, hydroxyl group, analkoxy group, a phenoxy group, a benzyloxy group or an aryloxy groupwith a polycyclic aromatic ring. The process involves applying thesolution to wood cellulose and exothermically reacting said plurality ofmolecules with the wood cellulose so the first molecule is covalentlybonded to the wood cellulose, and repeating the steps over the matrixdefined by the cellulose matrix to have a polymer shield of repeatingrings (FIG. 17D).

The process for the polymerization of wood cellulose, has the steps of:

-   -   (a) providing a solution containing a hydrophilic organic        solvent and a compound containing a trivalent, tetravalent or        pentavalent atom and a halogen atom, hydroxyl group, alkoxy        group, phnoxy group, benzyloxy group or an aryloxy group having        polycyclic aromatic ring (a polymer of a plurality of atoms        containing a trivalent, tetravalent or pentavalent atom and a        halogen atom, hydroxyl group, alkoxy group, phnoxy group,        benzyloxy group or an aryloxy group having polycyclic aromatic        ring might work poorly if it was disrupted (essentially        rendering it into the compounds previously set out) before being        introduced in the wood or afterwards because of the need to        align molecules);    -   (b) applying said solution to wood cellulose in the presence of        a catalytic compound as defined herein and,    -   (c) exothermically reacting said compound with the wood        cellulose so that the compound is covalently bonded to the wood        cellulose.

Boron Oxide, reacts with moisture/water within the wood or wood productsto generate Boric Acid that could be entrapped with the silicon shield.However, in the proportions stated, trimethylborate [TMB] reacts withwater/moisture within wood to undergo partial or full hydrolysis topolyborates or boric acid respectively (FIGS. 8 & 9). It could afterpartial hydrolysis react with methyltrihydroxysilane to form mixedboron-silicon polymers [FIG. 10] and with the proper catalyststriethylborate and other alkylborates could be incorporated into wood inthis manner.

A 0.5% solution of boric acid in acetone with an appropriate amount ofTMB can be used for a more stable formulation with a silicon donor suchas MTS.

Boron Halides, borontrichloride, borontribromide and borontrifluorideare examples of highly reactive compounds which will directly react withthe hydroxyl groups of wood cellulose or other compounds of wood to formrespective borates with the elimination of acid halides and can act asprocatalysts which do not react directly.

FIG. 7 shows the hydrolysis of MTS to methyltrihydroxysilane within thewood and its subsequent conversion to a polysiloxane that reacts withthe hydroxyl groups of wood cellulose forming the polymer shield in thepresence of the catalyst created in the wood (HCl) who MTS is used.

The main concern with the use of this reagent is the inevitablehydrochloric acid release. This problem can be addressed in variousways, one being to exposure of the treated wood to neutralizingsolutions. The other method taught herein would minimize the ratio ofprocatalyst to non-reactive alkyl hydroxy trivalent, pentavalent ortetravalent atom.

Silicon donors in one embodiment have the general formula R—Si(X)₃. Thissilicon donor can be represented by the general formula R—Si(X)₃; whereX is a halogen such as chlorine, bromine, iodine or an alkoxy group(selected from methoxy, ethoxy, propoxy, butoxy or an alkoxy group withthe number of carbon ranging from 3-20 in a straight chain or a branchedchain configuration); or a phenoxy group, a benzyloxy group or abenzyloxy group in which the benzene ring is replaced with a polycyclicaromatic ring. In the preferred embodiment X is part procatalyst(halogens) and part non-catalysts (alkoxyls).

The R group in the above silicon donor is an alkyl group ranging in acarbon chain length of 1-20 units in a straight chain or branched chainconfiguration. All these reagents are capable of undergoing the similartransformation as depicted in FIG. 7. While halogen substituted reagentsare very reactive and the reaction could be completed within a fewhours. The non-halogen substituted silicon reagents with this generalformula react only slowly (if at all) without a procatalyst and thecompletion of the reaction would require days under ordinary conditions.However this process is enhanced by the inclusion of acid or basecatalysts to the silicon reagents. These catalysts include, but are notlimited to, a metal alkoxide or an acid such as meta-phosphoric acid.

In the above general formula Silicon (Si) can be substituted withTitanium (Ti) or other tetravalent atoms and other factors remain thesame. A typical example would be Tetramethyltitanate. A generalrepresentation of the formula would be Ti[R]₄ where R=a halogen, analkoxy group, a phenoxy group or a benzyloxy group as defined above forthe silicon donor.

The following silicon reagents can also react with the hydroxyl groupsof wood components to render wood hydrophobic, insect and fireresistant:

-   -   (1) Dichlorodimethylsilane represented by the general formula:        [R]₂Si(X)₂; where R is an alkyl group ranging in carbon chain        length of 1-20 units as a straight chain or as a branched chain,        or a phenyl group or a benzyl group and X is a halogen, an        alkoxy, aryloxy or benzyloxy as defined above. Another common        example is dichlorodiphenyl-silane.

(2) Chlorotrimethylsilane represented by the general formula [R]₃Si—X,where R is the same selected from the above and X is the same selectedfrom the above. Another common example is Chlorotriphenylsilane.

(3) Hexamethydisilazane: This compound will form a trimethylsilylderivative of the hydroxyl groups of the components of wood or woodproducts with the evolution of nitrogen in combination with anappropriate catalyst. The catalyst may be phosphoric acid that by itselfmay render the wood fire resistant.

(4) Octyltriethoxysilane [OTS]. Is an excellent reagent that wouldfunction in a neutral environment. The drawback its high boiling point[difficulty drying] and slow reaction (more than a week aftertreatment). A waiting period of at least one month might be required tocomplete the process. The reagent is cost-effective and environmentallyclean. Possible improvements to speed up the reaction with the additionof catalysts [metaphosphoric acid or other acid catalyst] that couldalso provide fire proofing. Another common example isPropyltriethoxysilane.

Phosphorous reagents can also be used to derivative (modify) thehydroxyl groups of wood components to make the wood fire and insectresistant. Common reagents that can be used for this purpose are:

(1) Triethylphosphate: Here phosphorous is in the pentavalent state andthe trimethoxy groups are prone to hydrolysis by moisture/water withinthe wood and generate phosphoric acid or polyphosphoric acid which is afire retardant. The hydroxyl groups of the cellulose or other woodcomponents may directly react with triethylphosphate displacing one ormore of the methoxy groups with the formation of a chemical bond betweenthe phosphorous and the oxygen atoms of one or more of the hydroxylgroups. Another common example is trimethylphosphate.

(2) Triethylphosphite: Here phosphorous is in the trivalent state as intrimethylborate [TMB] and the mechanism of reaction with wood or woodcomponents are identical to those of TMB as described above. As is thecase with TMB there are two possibilities. Triethylphosphite can reactwith moisture/water in the wood or wood components to produce phosphoricacid or polyphosphoric acid within the wood to make it fire and insectresistant which when used in combination with a silicone reagent wouldtrap the phosphoric acid inside. Alternately triethylphosphite can reactwith one or more hydroxyl groups of wood cellulose or other componentsof wood to form permanent chemical bonds to render wood fire and insectresistant. Other common reagents are trimethylphosphite ortriphenylphosphite. Specific formulations include:

1. A composition consisting of a mixture of a pro-catalyst preferablymethyltrichlorosilane in the range from 0.25% to 4.0%; a siliconadditive, preferably methyltrimethoxysilane in the range of about 1.5 to40%, a boron additive, preferably trimethylborate, in an organic dryingsolvent, preferably ethyl alcohol, to treat all wood and wood productsto render to wood and wood products simultaneous hydrophobicity,microbial resistance and fire retardency. Using a kow as a standard, thesolvent's kow could be a kow less than zero. The preferred solventsgenerally have a kow of −0.15 or less. Less than 2.0 could work inlimited circumstances. A kow over 10 would be impractical. This generalrelationship of kow would apply to all solvents. The K_(ow), or OctonalWater partition coefficient, is simply a measure of the hydrophobicity(water repulsing) of an organic compound. The more hydrophobic acompound, the less soluable it is.

While Kow is a standard for differentiation purposes, different organicsolvents can work with different Kow. Hence, the better range is a log(K_(ow)) less than 1.0 or even one less than zero. However, Kow alonedoes not define the reactants since water has a Kow of 1. Also mixturesof solvents may work, even those containing water, as long as theoverall solvent allow for the function described herein, namely allowingthe reactants to be drawn from the solution into the wood at a desiredrate of speed and without oligomerization in the solvent.

2. A composition for treatment of all wood and wood products, as setforth above consisting of a mixture of a pro-catalyst in the range of0.25 to 4% represented by the formula R—X(Y)₃ where R is selected from agroup of straight or branch chain alkyl substituents ranging in carbonnumbers from 2-18 (eg. Methyl, ethyl, propyl, isopropyl, butyl,isobutyl, tertiary butyl, pentyl, isopentyl etc.), and aryl substituentsphenyl and benzyl; X is an atom selected from the group Si, Ge, Sn, PB,TI, ZR and Y is selected from a group consisting of Chlorine, Bromine,Iodine and Flourine; and a silicon additive in the range of about 3.0 to40%, represented by the formula R—X(Y)₃, where R and X represents thesame groups as above for the silicon non-catalyst, but Y is selectedfrom a group consisting of methoxy, ethoxy, propoxy, butoxy, t-butoxy,pentoxy, isopentoxy, hexyloxy, phenoxy and benzyloxy substituents in anorganic drying solvent selected from a group consisting of methanol,ethanol, propanol, isopropanol, n-butanol, isobutanol, tertiary butanol,pentanol, isopentanol, benzyl alcohol, acetone, tetrahydrofuran, dioxaneand acetonitile to render wood and wood products simultaneouslyhydrophobic, microbial resistant and fire retardant.

3. A composition for the treatment of all wood and wood productsconsisting of a mixture of a pro-catalyst according to claim 1, as it isdefined above; a silicon additive as defined and trimethyborate[B(OMe)₃] in the range of about 0.25 to 35% in an organic drying solventas defined, to render to the wood hydrophobic, and microbial resistanceand fire retardant simultaneously.

4. A composition for the treatment of all wood and wood products,consisting of a mixture of reactive silicon reagent, a silicon additiveand another reactive reagent in which trimethyborate is replaced with acompound having the general formula X (R)₃, where X is selected from agroup of atoms consisting of B, Al, Ga, In, Tl, P, As, Sb, Bi and V andR is selected from a group consisting of F, Cl, Br, I, methoxy, ethoxy,propoxy, isoporpoxy, isobutoxy, pentoxy, isopentoxy, butoxy,tertiarybutoxy, phenoxy and benzyloxy substituents to render to wood andwood products hydrophobicity, microbial resistance and fire retardancy.

One embodiment of Applicant's invention is a solution as shown inExample 1:

EXAMPLE-1 Preparation of Reagents for Wood Treatments

Basic Silicon Formula (FRF-S): [Silicon]

In a 250 mL reagent bottle was added 137 mL of reagent alcohol was addedfollowed by 60 mL of methyltrimethoxysilane (MTMS). After mixing the twoagents by shaking; 3.0 mL of methyltrichlorosilane (MTS) was added froma pipette to this solution and kept ready for treatment. This clearcolorless formula was found to be stable for the next several monthswith no appearance of any residue or cloudiness.

The drying agent is denatured alcohol available as a gasoline additive.This could be substituted with wood alcohol which is commerciallyavailable as an industrial solvent. The formula is made of 30%methyltrimethoxysilane (MTMS) and 1.5% methyltrichlorosilane (MTS).

Basic Boron-Silicon Formula (FRF-BS): [Boron, Silicon]

This formula is made of 30% methyltrimethoxysilane; 3% trimethyborateand 1.5% methytrichlorosilane (MTS) in denatured alcohol. This boron andsilicon containing treatment formula was prepared as above except, 131mL of alcohol, 60.0 mL of MTMS, 6.0 mL of trimethylborate and 3.0 mL ofMTS was used. The reagent was found to be stable without decomposition,residue formation or color change for the next several months ofobservation.

Modified Boron-Silicon Formula (FRF-MBS) [Modified Boron, Silicon]

This formula is made as a substitute for FRF-BS. The formula consists of30% methyltrimethoxysilane (MTMS); 2% boric acid and 1.5%methyltrichlorosilane (MTS) in denatured alcohol. The formula consistedof 137 mL of denatured alcohol, 60 mL of MTMS, 3.0 mL of MTS and 4.0grams of boric acid. On shaking this mixture for 10 minutes completedissolution of the boric acid occurred and a crystal clear colorlesssolution was obtained which was also stable for the next several monthsof observation.

EXAMPLE-2

Treatment of Wood:

In a closed bell jar 200 mL of the appropriate reagents, (FRF-S; FRF-BSand FRF-MBS formula prepared as specified above) were poured and threewood pieces were placed inside such that about three fourth portions ofthe wood blocks were immersed in the reagents. 1×1″ blocks of red oakand yellow pine as supplied (raw wood) were used for this study. Thewood pieces were allowed to remain in this jar overnight during whichtime the reagents were drawn inside the wood. The temperature of thereagent solution increased by about 5 degree Centigrade during theinitial exposure time of about 20 minutes by which time the penetrationof the formula to the top surface of the wood was complete.

The wood pieces were allowed to air dry and periodically they wereweighed to constant weight gain (about 48 hours). From this theincorporation of reagents to wood was calculated on a weight basis. Theresults are tabulated in the following table. Wood Sample Wood Dimension% Weight Gain % Si % B Red Oak 1 × 1″ 5.48 [FRF-S] 5.48 0.0 Red Oak 1 ×1″ 5.85 [FRF-BS] 5.32 0.53 Red Oak 1 × 1″ 3.13 [FRF-MBS] 2.98 0.25Yellow Pine 1 × 1″  9.6 [FRF-S] 9.60 0.0 Yellow Pine 1 × 1″  9.1[FRF-BS] 8.19 0.91 Yellow Pine 1 × 1″ 8.68 [FRF-MBS] 8.10 0.58

The above results show that red oak, a hard wood incorporates lessreagents compared to soft wood (yellow pine) under identical treatmentconditions. Although the desired levels of boron and siliconincorporation was achieved by this process, additional experimentationwould be needed to see whether increasing the treatment time wouldincrease reagent incorporations to the samples if desired.

The results are averages of three independent determinations.

EXAMPLE-3

Hydrophobicity:

Pieces of red oak and yellow pine treated as above in example-2 anduntreated wood (red oak and yellow pine) blocks were selected at randomand they were completely immersed in water (distilled water, immersionsaccomplished by placing a glass stopper over the wood piece such thatthe entire wood is completely immersed in water) for varying periods oftime, and the weight of water absorbed as a function of time wasdetermined for each treatment. These comparative results obtained underidentical conditions are summarized in the accompanying graphs: [for redoak and yellow pine]. The results clearly illustrates that there arestriking differences in the water absorption of treated wood with theuntreated control. FIG. 18A & 18B?

The results show that the apparent water absorption for red oak andyellow pine are similar although their silicon and boron contents differsignificantly. Similarly FRF-S treated wood samples and FRF-BS treatedwood samples exhibit similar hydrophobicity indicating that boronincorporation is not adversely affecting hydrophobicity of treated woodsamples. These results indicate that boron is trapped in asilicate-cellulose matrix and water is precluded from coming in contactwith boron due to the silicon shield.

The difference between treated wood and untreated wood in terms of waterabsorption at different time intervals was phenomenal. FIG. 18-A showsthe results with southern pine, a soft wood that has not beenconditioned. At 30 minutes the untreated wood absorbed more than 20% ofwater while treated wood with both formulae had less than 2% waterabsorption. A comparison of water absorption at 30 minutes with that of60 minutes for both samples indicate that further water absorption wasless than 1.0% indicating that water is occluded initially on surfacebut not absorbed significantly as a function of time. In one houruntreated Southern pine of the same dimension and weight absorbed aremarkable 30% of water. Similar results were obtained with red oak(FIG. 18-B) that absorbed less water than southern pine as expected.

It should be noted that there has been complete immersion of wood withinwater for the entire indicated periods as opposed to floating the woodin water for 15 minutes or exposing wood under running water for a fewminutes to evaluate water absorption by other investigators in the citedup on prior art.

EXAMPLE-4

Retention:

The water solution remaining after immersion of the respective treatedsamples for 24 hours performed as in Example-3 was transferred to apreviously weighed beaker. First the FRF-S treated sample was examined.The solution was allowed to evaporate at room temperature. No residuewas left in the beaker after complete evaporation. The beaker wasweighed again. The results showed that there was no significantdifference in the weight of the beaker before and after evaporation. Theresults showed that no silicon was leached out from the FRF-S treatedwood pieces and the silicon is irreversibly bound to the wood molecules.

The FRF-BS treated sample and the FRF-MBS treated samples were similarlyimmersed and evaporation of the water showed minute residues, but theweights differences were insignificant indicating that both boron andsilicon were retained within the wood without significant leaching outin complete agreement with expectations.

The wood pieces after leaching with water for 24 hours as above wereweighed to constant weight. Twelve to twenty four (12-24) hours afterthe leaching experiment was performed the wood pieces returned to theirinitial weight. This experiment adduce further independent evidence thatno incorporated reagents (boron and silicon) were leached out of thewood during prolonged immersion of treated wood in water. During theremaining one month a weight of loss of less than 0.5% was observedfurther substantiating that boron and silicon were not leaching fromwood treated with the inventive formulae.

Because many varying and different embodiments may be made within thescope of the inventive concept herein taught and because manymodifications may be made in the embodiment(s) herein detailed inaccordance with the descriptive requirements of the law, it is to beunderstood that the details herein are to be interpreted as illustrativeand not in a limiting sense.

1. A process for treating wood having wood cellulose having a pluralityof hydroxyl groups comprising the steps of: providing a solutioncomprised of: a non-water-based hydrophilic organic solvent and a solutecompound having at least one plurality of functional groups wherein eachof which functional group includes: an atom selected from the groupconsisting of trivalent, tetravalent, pentavalent atoms and combinationsthereof, wherein said atom is bonded to a halogen atom or a functionalgroup selected from the group consisting of a hydroxyl group, alkoxygroup, phenoxy group, benzyloxy group, an aryloxy group having apolycyclic aromatic ring, and combinations thereof, applying saidsolution to the wood cellulose, reacting said functional groups to formcovalent bonds with other functional groups of said solute and to saidwood cellulose.
 2. The process according to claim 1 further comprisingthe step of maintaining said solute compound functional groups asmonomers prior to the applying said solution to wood having woodcellulose,
 3. The process according to claim 2 further comprising thesteps of simultaneous reaction and diffusion of the functional groups inthe wood and self-initiating exothermic reaction of said functionalgroups to form covalent bonds with other functional groups of saidsolute and to said wood cellulose.
 4. The process of claim 1 wherein theprocess further comprises the step of adding a catalyst to the solution.5. The process of claim 4 wherein the catalyst comprises a substancewhich effects the exothermic reaction of the functional group so thatthe functional group bonds from the trivalent, tetravalent orpentavalent atom across an oxygen of the cellulose hydroxyl group. 6.The process of claim 5 wherein the catalyst is added to the woodcellulose after application of said solution to the wood cellulose. 7.The process of claim 5 wherein the catalyst is added to the solutionprior to application of the solution to the wood cellulose.
 8. Theprocess of claim 5 wherein the catalyst is an acid or a base.
 9. Theprocess of claim 5 wherein the acid is produced by a pro-catalystdefined as a molecule producing an acid or base in the presence of woodcellulose or water in wood cellulose.
 10. The process of claim 5 whereinthe acid is in the range of 0.05-10% of the solution.
 11. The process ofclaim 10 wherein the acid is in the range from 0.05 to 4.9% of thesolution.
 12. The process of claim 9 wherein the functional groupcomprises at least one functional group having a group concentrationwhich at least one reactant group is not a pro-catalyst and wherein thecatalyst has a catalyst concentration which concentration is less than17% the group concentration.
 13. The process of claim 12 wherein thecatalyst concentration is less than 5% of the group concentration. 14.The process of claim 8 wherein the acid has a pKa of 4 or less.
 15. Theprocess of claim 14 wherein the acid has a pKa below 2.5
 16. The processof claim 8 wherein the base has a pKb above 9.00.
 17. The process ofclaim 8 wherein the acid or base is from the group consisting of acidsfrom Akyl-silicon halides, acids from alkyl-halide monomers withtrivalent, tetravalent and pentavalent atoms, hydrochloric,meta-phosphoric acid, poly-phosphoric acid, bases from metal alkoxides,phosphoric acid and combinations thereof.
 18. The process of claim 8wherein the acid or base is in the range of 0.01-10% in situ the wood.19. The process of claim 9 wherein the pro-catalyst is a moleculecomprised of silicone and a halogen.
 20. The process of claim 9 whereinthe functional groups further comprises non-pro-catalyst functionalgroups in the range of 1-65%.
 21. The process of claim 20 wherein thenon-pro-catalyst functional groups react exothermically andspontaneously with wood in the presence of a pro-catalyst, acid or base.22. The process of claim 20 wherein the non-catalytic reagents wouldinclude hydroxyl and alkoxy bonded trivalent, pentavalent andtetravalent atoms.
 23. The process of claim 1 wherein the concentrationof water in the solvent is between 0 and 8%.
 24. The process of claim 23wherein the concentration of water is between 0 and 0.5%.
 25. Theprocess of claim 1 further comprising the step of agitating the solutionprior to applying to wood cellulose.
 26. The process of claim 1 whereinthe concentration of non-hydrophilic organic solvents is in the rangefrom 0-20%.
 27. The process of claim 26 wherein the percentage ofnon-hydrophilic organic solvents is in a range of 0 to 10%.
 28. Theprocess of claim 1 wherein the hydrophilic organic solvent is at aconcentration of at least 10% of the solution.
 29. The process of claim27 wherein hydrophilic organic solvents are at a concentration of30%-99.9% of the solution.
 30. The process of claim 1 wherein thesolution is less than 20% oligomers of the functional groups prior toapplying the solution to the wood.
 31. The method of claim 1 wherein theorganic solvent is an organic solvent with a (K_(ow)) less than 10.0.32. The method of claim 31 wherein the organic solvent is an organicsolvent with a (k_(ow)) less than 1.0.
 33. The method of claim 32wherein the organic solvent is an organic solvent with a less than 0.34. The process of claim 1 further comprising the step of: adding atleast one non-reactive additive to the wood cellulose that enhances adesired property selected from the group consisting of (1) fireresistance, (2) insect resistance, (3) moisture resistance (4) color,(5) adhesion, (6) insulation, and (7) combinations thereof.
 35. Theprocess of claim 34 wherein the step of adding at least one non reactiveadditive further comprises adding the additive to the solution.
 36. Theprocess of claim 34 wherein the step of adding the at least onenon-reactive additive occurs before reacting the functional groups tobond with the wood cellulose.
 37. The process of claim 34 wherein theadditive is from the group consisting of: 1) diatimatious earth, 2)sodium silicates, 3) boron or silicon salts, 4) boric acid, 5) trimethy(trialkyl) borate, 6) Boron Halides (BF3, BCl3, etc.), 7) BoricAnhydride (boron oxide), 8) phosphorous compounds, 9) copper compounds,10) metal alkoxide, 11) meta-phosphoric acid; 12) a hydrophobicreagents, 13) phosphoric acid, 14) metaphoshoric acid, and 15)combinations thereof.
 38. The process of claim 1 wherein the solutecompound comprises functional groups from the group consisting ofR-Xa-Xb₃, R₃-Xa-Xb, R₂-Xa-Xb₂, R₁-Xa-Xb₂, R₂-Xa-Xb₁, R₄-Xa, XaR₃, andcombinations thereof wherein R is the carbon compound, Xa is thetrivalent, tetravalent or pentavalent atom and Xb is a halogen or oxygroup.
 39. The process of claim 37 wherein the solute compound comprisesfunctional groups where Xb is a halogen and functional groups where Xbis from a group consisting of alkoxy groups, hydroxyl groups andcombinations thereof.
 40. The process according to claim 1, wherein thewood cellulose has an original weight and wherein the duration oftreatment attains a weight of compound which is covalently bonded to thewood cellulose having a range of 0.1 to 10 weight percent of theoriginal weight of the wood cellulose.
 41. The process according toclaim 1, further comprising forming cyclic interlocking molecules havingas a part of the cyclic structure at least two carbons within thecellulose and at least two of the trivalent, tetravalent or pentavalentatoms from the functional groups.
 42. The process of claim 8 furthercomprising the step of exposing the acids introduced into the wood to anacid reducing compound subsequent to the treatment.
 43. The process ofclaim 42 further comprising the step of introducing an acid reducingchemical into the wood prior to the exposure of the wood cellulose tothe acid.
 44. The process of claim 8 further comprising the step ofexposing the bases introduced into the wood to an base neutralizingcompound subsequent to the exposure of the wood cellulose to the acid.45. The process of claim 44 further comprising the step of introducingan base neutralizing chemical into the wood prior to the exposure of thewood cellulose to the base.
 46. A process according to claim 1 whereinthe wood cellulose comprises water and wherein the functional groups aresolvated by the water in the wood prior to being covalently bonded tothe hydroxyl groups of said wood cellulose.
 47. The process according toclaim 46 further comprising the step of adding water to the woodcellulose prior to applying the solution to the wood cellulose
 48. Aprocess for treating wood cellulose having a plurality of hydroxylgroups comprising the steps of providing a solution comprised of anon-water-based hydrophilic organic solvent and a solute having aplurality of monomers comprising an atom selected from the groupconsisting of tri-valent, tetravalent, pentavalent atoms, andcombinations thereof which atom is bonded to a halogen atom or afunctional group selected from the group consisting of a hydroxyl group,alkoxy group, phenoxy group, benzyloxy group and an aryloxy group havinga polycyclic aromatic ring and combinations thereof, applying saidsolution to the wood cellulose and simultaneously diffusing saidsolution within said wood and reacting said solute to form covalentbonds; and forming a matrix structure comprising reacted monomers andwood cellulose.
 49. The process of claim 48 further comprising the stepof: adding at least one non-reactive additive that enhances a desiredproperty selected from the group consisting of: fire resistance, insectresistance, moisture resistance color, adhesion, insulation andcombinations thereof.
 50. The process of claim 49 wherein the step ofadding the at least one non-reactive additive occurs before covalentlybonding the compound to the wood cellulose.
 51. The process according toclaim 48, further comprising a step of exposing the wood to ultra-soundsonification while applying said solution.
 52. The process of claim 48herein the monomer, as a percent of solution, is over 5% of the solutionby volume.
 53. The process of claim 48 herein the monomer, as apercentage of total solution is over 10% by volume.
 54. The process ofclaim 48 wherein the monomer comprises at least two separate monomersbeing: (i) a pro-catalyst reactant diffused as a chemical from thesolution and bonding with wood in conjunction with water in the wood andgenerating in the bonding a catalyst; and (ii) a non-pro-catalystreactant diffused as a chemical from the solution and bonding with woodcellulose in the presence of the catalyst generated by the pro-catalyst.55. The process of claim 54 wherein the solution comprises: (A) acomposition consisting of a mixture of a pro-catalyst in the range from0.25% to 4.0%; (B) a silicon additive which is not a pro-catalyst in therange of about 1.5 to 40% and wherein the hydrophillic organic solventis further defined as an organic drying solvent.
 56. The process ofclaim 55 wherein the solution further comprises a boron additive. 57.The process of claim 54 wherein the solution comprises: (A) apro-catalyst in the range of 0.25 to 4% of the total solutionrepresented by the formula R—X(Y)₃ where (i) R and Y are selected from agroup of straight or branch chain alkyl substituents ranging in carbonnumbers from 2-18 (eg. Methyl, ethyl, propyl, isopropyl, butyl,isobutyl, tertiary butyl, pentyl, isopentyl etc.), aryl substituentsphenyl benzyl and combinations thereof or a group consisting ofChlorine, Bromine, Iodine, Flourine and combinations thereof, and (ii) Xis an atom selected from the group consisting of Si, Ge, Sn, PB, TI, ZRand combinations thereof; and (B) a silicon additive in the range ofabout 3.0 to 40%, represented by the formula R—X(Y)₃, wherein: (i) R isselected from a group of straight or branch chain alkyl substituentsranging in carbon numbers from 2-18 (eg. Methyl, ethyl, propyl,isopropyl, butyl, isobutyl, tertiary butyl, pentyl, isopentyl etc.),aryl substituents phenyl benzyl and any combinations thereof, and (ii) Xis an atom selected from the group consisting of Si, Ge, Sn, PB, TI, ZRand combinations thereof; and (iii) Y is selected from a groupconsisting of methoxy, ethoxy, propoxy, butoxy, t-butoxy, pentoxy,isopentoxy, hexyloxy, phenoxy, benzyloxy and combinations thereof; and(C) an organic drying solvent selected from a group consisting ofmethanol, ethanol, propanol, isopropanol, n-butanol, isobutanol,tertiary butanol, pentanol, isopentanol, benzyl alcohol, acetone,tetrahydrofuran, dioxane, acetonitile and combinations thereof.
 58. Theprocess of claim 64 wherein the solution further comprises a boratecompound in the range of about 0.25 to 35%.
 59. The process of claim 48wherein the solution further comprises X (R)₃, where X is selected froma group of atoms consisting of B, Al, Ga, In, Tl, P, As, Sb, Bi, V andother combinations thereof, and R is selected from a group consisting ofF, Cl, Br, I, methoxy, ethoxy, propoxy, isoporpoxy, isobutoxy, pentoxy,isopentoxy, butoxy, tertiarybutoxy, phenoxy, benzyloxy and combinationsthereof.
 60. The process of claim 48 further comprising adding atraceable additive.
 61. A product produced utilizing wood cellulosecomprising a plurality of cyclic rings comprised of a trivalent,pentavalent or tetravalent compound and at least one carbon and oneoxygen of the wood cellulose made from the process of exposing woodcellulose to a solution comprised of (a) a non-water-based hydrophilicorganic solvent; and (b) a solute compound having a functional groupwhich includes a monomer comprising: (i) an atom selected from the groupconsisting of trivalent, tetravalent and pentavalent atoms, wherein saidatom is bonded to (A) a halogen atom or (B) a functional group selectedfrom the group consisting of a hydroxyl group, alkoxy group, phenoxygroup, benzyloxy group and an aryloxy group having a polycyclic aromaticring.
 62. The product of claim 61 wherein the cyclic rings areinterlocking.
 63. The product of claim 62 wherein the rings are 7-12unit rings.